Method of molding and apparatus therefor



' Dec. 1, 1931. BONSIEUR 1,834,763

METHOD OF MOLDING AND APPARATUS THEREFOR Filed April 16, 1927 7 I, W I B /22 ATTORNEY Patented Dec. 1, 1931 UNITED STATES PATENT OFFICE LE BOHSIEUR, 0F ELYRIA, OHIO, ASBIGNOB TO THE GENERAL INDUSTRIES 00., 01'

. ELYBIA, OHIO, A CORPORATION 01 OEIO mrrzon or momma Ann arrm'rus rimnnroa Application. filed April 16, 1921. serial in. 184,207.

My invention relates toim rovements in methods for making forming ies, and forming dies, as articles of manufacture, which are adapted for subsequent use in molding articles from plastic compositions.

An object of my invention is to inexpensively rovide a die capable of being employed in a mold adapted for the forming of articles from plastic materials, such'as phenolic condensation roducts, or like materials 'adapted to e molded under the influence of heat and pressure.

Another object of my invention is to inexpensively rovide a die that will not deteriorate un er high heat or high pressure.

' Another object of my invention is to accomplish the making of a die, by workmen of ordinary skill, which will be durable in construction and economical to manufac- 80 ture.

Another object of my invention is to accomplish the making of a die, by workmen of ordinary skill, which will be an accurate replica of the pattern.

Another object of my invention is to inexpensively provide a die for the making of variously formed articles, the die-havin a metallic face so backed by a heat conducting material as to be capable of withstanding high pressure and hi h heat, and communicating, efficiently t e heat to molding material.

The above and other objects of my invention will become apparent from reference to the following description of an embodiment method thereof. in which description reference will be had to the accompanying drawings employed to explain the method,

and forming a part of this specification.

Referring to the drawings:

Fig. 1 is a top plan view of-a pattern capable of being reproduced by the method of my invention;

Fig. 2 is a transverse sectional view ofthe pattern of Fig. 1; Fig. 3 is a transverse sectional view of the pattern of Fig. 1, with an electrolytically deposited layer of'metal disposed upon one surface thereof; and

Fig. 4 is a transverse sectional view of dies coating from the pattern. Sometimes,

ploy a wax pattern and in such cases heat of resulting from the use of my improved process in their respective relative positions during the heating and pressing operations of the subsequent process of molding articles by use of the dies.

Referring. now to all the figures of the drawings, in which like reference characters are employed to designate like parts; in Fig. 1, I show a master pattern constructed of a non-electro-conductive material, such as wood or wax, of which molded replicas are desired to be made of phenolic condensation products or like plastic materials, and for the making of which, it is desired to construct a die.

In car g out the process, a thin even coating 0 an electro-conductive finely comminuted powdered material, such as plumbago or aluminum paint, is applied to the surface to be plated, b first applying, a thin coat of bees wax, bu g the same, and then applying the comminuted material, the surplus powdered material being removed preferably with a fine camels hair brush.

The pattern 1, is then immersed in the electro-plating bath and a layer of copper, nickel, steel or other suitable metal material 2, is

de'positedupon the outer surface of the pattern at 6; the pattern being allowed toremain'in the bath until a plate of the desired metallic material of preferably a thickness of is de ited upon the plumbago treated surface 0 the pattern.

The pattern with the plating adhering to its surface is removed from the bath, and the plate 2 is their removed from the pattern in any suitable way, such as by subjecting it to heat, the difi'erence in the coeflicient of expansion of the metal and the non-metallic pattern effecting a stripping of the late arelatively low temperature may be applied to the pattern and platin whereby the wax is melted away from the p ating.

The surface of the metallic plate, which has thus been removed from contact with the face of the pattern, forms a metallic die face, may be placed in position at the top of a mold box, as shown in 4.

The interm iate space 5 is filled with a aluminum paint or the ike, electro-de mixture of litharge, lycerine, and brass filings, preferably in t e proportion of four arts by weight litharge to one part glycerine.

his mixture furnishes a suitable base for the die the brass filings increasing the cfliciency of heat conduction from the steam heating coils 7, of the die press carried by a pair of press jaws 22 and 23 as shown in the drawlngs in fragmentary view only. The annular grooves 24, become filled with the litharge mixture which is retained within the side walls of the mold element 4.

An upper die plate 3 is rovided conforming to the shape of the an or side of the pattern by likewise coatin itwith plumbago, s1ting a metallic late of the desired thic ess thereon, as in t e case of the plate 2 formed on the outer surface of the pattern as previously described.

The 'die face element 3, is likewise backed by a mixture of litharge, brass filings and glycerine or like heat conductin relatively hard non-compressible material p aced in the mold element, such backin being shown at 8. 7 The dies 2 and 3 are enc osed, as shown, by providing'metallic flask walls 9, 10 and 11 for the concave die 12-, 13 and 14 for the convex die 3, having the face 15. Guide pins id and 17, and an ejectin pin 18, are provided for aligning the fins 1 sections and for ejecting the molded article in a manner commonly cm )loyed in the use of such pins for moids of t is character.

in molding articles, such as the radio dial illustrated, between dies formed as above described, th e concavely faced die is placed on the platen 23, which is heated by steam coils 7; and the molding material consisting of powdered henolic condensation material or i like material, preferably in the form of a pill having the requisite amount of material. in it, is placed within the cavity formed by the two (1168. The upper die element, having a convex die face, is then superposed into the lower element, being-guided to position therein by guiding pins 16 and 17.

Heat and pressure is then applied 1) the heated press elements 22 and 23, whic are pressed towards each other, compressing and heat treatin the powdered material above referred to in the mold which is thus caused to assume the plastic state, and flows to all parts of the recess between the die faces 6 and 15, which recess conforms to the contour of a radio dial or other article to be molded. The surplus molding material escapes through to recesses 20 and 21, provided for that purpose, during the period while the side plates 12, approach opposing side plates, as 9 and 10 of the lower die element. The upper and lower die plates are brought together and the heatin and pressing is effected for the proper period of time determined by experience.

Upon completion of the moldin operation, cold water may be circulated t ough the heating pipes 7 to assist in cooling the mold and the article contained therein.

Having thus described my invention in a specific embodiment and in a process employ ing certain steps, I am aware that numerous and extensive departures may be made from the embodiment herein illustrated and described and b varying the number of the.

process steps, ut without essentially changpressure reslstivity and rendered of high eat conductivity by having mixed therewith particles of metal having high heat'conduc tivity, the exposed surface of the facing being that surface thereof which was removed irom intimate contact with the article surace.

2. A method of forming a mold die for molding articles having a convexly formed surface, which includes appplying a thin smooth coating of wax material to such surface, applying finely comminuted metallic powder to the waxed surface, electro-plating a metallic facing of substantial thickness upon the powder, separating the facing from the article, backing the facing with a plastic composition comprising a mixture of. litharge and glycerin to render it hard setting and of high pressure and heat resistivity and com taming particles of highl heat conductive metal to render it of high eat conductivity, the exposed surface of the facing being that surface thereof which was removed from in timate contact with the article surface.

3. A method of forming a mold die for molding articles having a concavely formed surface, which includes appl 'ng a thin smooth coating of wax materia to suchsurface, applying finely comminuted metallic powder to the waxed surface, electrolating a metallic facing of substantial thickness upon the powder, separating the facing from the article, backing the facing with a lastic composition comprising litharge and g cerin approximately in the proportions 0 four parts by weight of litharge to one part of glycerin to render it hard setting and of high pressure and heat resistivity and comprising also particles of metal having high heat conductivity to render the set mixture composed of litharge,

of high heat conductivity, the exposed surface of the facing being that surface thereof which was removed from intimate contact with the article surface.

4. In a molding device for molding articles from plastic material under relativel great heat and pressure, a facing having t e configuration of the article to be molded, a molding flask for supportin the same and a back' ing for the facing for olding it in position in the flask and for transmittin heat and pressure to the facing, said bac 'ng being g1 oerin and metal filings, whereby it is rendiired hard setting and of high pressure resistivity and high heat conductivit 5. In a molding device for molding articles from plastic material requiring relatively great pressure and high temperature, a flask, a heat conducting pressure applying cover for the flask, means for a plymg heat and pressure to the cover, a mo din facing positioned in the flask and a backm filling the space enclosed by the facing, the ask and the cover, said backing being a composition of material comprising litharge and glycerin in proportion to render the composition plastic enough to fill the interstices in said enclosed space and, to render it hard setting and mec anically strong to resist the required said molding pressure and comprising metal filings in suificient amount to transmit to the facing the required said heat.

In testimony whereof I hereunto afiix my signature this 24th day of Februar 1927.

LE BON IEU'R. 

